Apparatus, system and method for an air bearing stage for component or devices

ABSTRACT

The disclosure provides an apparatus, system and method for a moveable bearing stage that allows for highly refined alignment and placement, and particularly planar alignment and placement, of component or devices through the use of robotics. The apparatus, system and method of providing at least a planar alignment of at least one component or device in relation to a secondary reference plane may include at least: a frame and stator assembly, having, at an upper portion thereof, at least a semi-spherical receiving interface; a movable assembly that moves within the frame and stator assembly, and that is connectively associated therewith by at least a plurality of springs; a semi-spherical stage, suitable for reception by the semi-spherical receiving interface and capable of at least rotational movement therewithin; a chuck within the semi-spherical stage and capable of at least co-planar, post-planar, and ante-planar positioning in relation to a plane provided by a topmost portion of the semispherical stage, wherein the chuck is capable of receiving the component or device; and at least two gripper jaws suitable for receiving and holding, at an upper portion thereof, the component or device, wherein the two gripper jaws comprise, at a lower portion thereof, at least ramps capable of physically interacting with ones of the motion stops.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation Application of U.S. application Ser.No. 16/461,094, filed May 15, 2019, entitled “Apparatus, System andMethod for an Air Bearing Stage for Component or Devices” which is anational stage application of International Patent Application No.PCT/US2017/062065, filed Nov. 16, 2017, entitled “Apparatus, System andMethod for an Air Bearing Stage for Component or Devices” which claimspriority to U.S. provisional Application No. 62/422,857, filed Nov. 16,2016, entitled “Apparatus and Method for an Air Bearing Stage forComponent or Devices,” which is hereby incorporated by reference.

BACKGROUND Field of the Disclosure

The disclosure relates generally to manufacturing equipment, such asrobotic equipment, and, more particularly, to an apparatus, system andmethod for an air bearing stage used to spatially align, place orconnect components or devices, such as components of an apparatus, forassembly or other processing.

Description of the Background

Automated or semi-automated equipment is commonly employed in manyindustrial applications. For example, automated or semi-automatedequipment is often employed to make connections between electroniccomponents. Oftentimes, these connections, and/or connection associatedor prescribed alignments and placements, may typically require aprescribed accuracy, delicateness and precision.

One known effort to align, place or connect devices or components isdisclosed in U.S. Pat. No. 4,789,292, the entire disclosure of which ishereby incorporated by reference as if being set forth in its entiretyherein. The approach described therein uses dual ball-and-socketassemblies coupled together to provide enhanced range of movement inaligning and placing electronic components. However, that particularapproach may be unsuitable in certain cases, such as in which planaralignment of irregularly shaped devices or components is needed.

Therefore, the need exists for a moveable bearing stage that allows forhighly refined alignment and placement, and particularly planaralignment and placement, of component or devices or components throughthe use of automation or semi-automation, like robotics.

SUMMARY

Certain embodiments of the present invention include an apparatus,system and method for a moveable bearing stage that allows for highlyrefined alignment and placement, and particularly planar alignment andplacement, of component or devices through the use of robotics. Moreparticularly, an exemplary apparatus, system and method of providing atleast a planar alignment of at least one component or device in relationto a secondary reference plane may include at least: a frame and statorassembly, having, at an upper portion thereof, at least a semi-sphericalreceiving interface; a movable assembly that moves within the frame andstator assembly, and that is connectively associated therewith by atleast a plurality of springs; a semi-spherical stage, suitable forreception by the semi-spherical receiving interface and capable of atleast rotational movement therewithin; a chuck within the semi-sphericalstage and capable of at least co-planar, post-planar, and ante-planarpositioning in relation to a plane provided by a topmost portion of thesemispherical stage, wherein the chuck is capable of receiving thecomponent or device; and at least two gripper jaws suitable forreceiving and holding, at an upper portion thereof, the component ordevice, wherein the two gripper jaws comprise, at a lower portionthereof, at least ramps capable of physically interacting with ones ofthe motion stops. By way of example, the reference plane may also be apitch-adjustable surface.

The moving assembly may include at least a floating yoke portion, havingassociated therewith at least: a plurality of linear motion stops; and atactile portion that physically interacts with the plurality of linearmotion stops and that is suitable for assessing a plane of a topmostportion of the component or device in relation to a second referenceplane. The movable assembly may allow for placement of a plane providedby the topmost portion of the component or device into a suitableposition with respect to the second reference plane so as to allow forprocessing of the component or device and a second electronic elementthat provides the second reference plane. The apparatus, system andmethod may further include: an air inlet suitable for enhancing thefloat of the floating yoke portion; and a vacuum associated with thechuck and suitable for grasping the component or device.

More specifically, an exemplary method of providing at least a planaralignment of at least one component or device in relation to a secondaryreference plane may include at least: centering an air bearing stageusing at least synchronous jaw grippers having ramps associatedtherewith, and interaction of those ramps with one or more motionlimiters; moving the air bearing stage in multiple axes; providing thecomponent or device to the centered, moved air bearing stage; switchingoff an air float affecting the component or device; actuating a vacuumto grip the component or device; closing the jaw grippers on thecomponent or device; extending a tactile system to assess a planaralignment of the component or device with the secondary reference plane;switching on the air float to affect the component or device; andengaging the component or device to an element having the secondaryreference plane based at least on an outcome of the extension of thetactile system.

Thus, the disclosure provides at least an apparatus, system and methodfor a moveable air bearing stage that allows for highly refinedalignment and placement, and particularly planar alignment andplacement, of component or devices for and during use in automated orsemi-automated, such as in robotics-based, manufacturing processes.

BRIEF DESCRIPTION OF THE DRAWINGS

The exemplary compositions, systems, and methods shall be describedhereinafter with reference to the attached drawings, which are given asnon-limiting examples only, in which:

FIG. 1 is an illustration of features of the disclosed embodiments;

FIG. 2A is an illustration of features of the disclosed embodiments;

FIG. 2B is an illustration of features of the disclosed embodiments;

FIG. 2C is an illustration of features of the disclosed embodiments;

FIG. 3 is an illustration of features of the disclosed embodiments;

FIG. 4 is an illustration of features of the disclosed embodiments;

FIG. 5 is an illustration of features of the disclosed embodiments;

FIG. 6 is an illustration of features of the disclosed embodiments;

FIG. 7 is an illustration of features of the disclosed embodiments;

FIG. 8 is an illustration of features of the disclosed embodiments;

FIG. 9 is an illustration of features of the disclosed embodiments;

FIG. 10 is an illustration of features of the disclosed embodiments;

FIG. 11A is an illustration of features of the disclosed embodiments;

FIG. 11B is an illustration of features of the disclosed embodiments;

FIG. 11C is an illustration of features of the disclosed embodiments;

FIG. 12A is an illustration of features of the disclosed embodiments;

FIG. 12B is an illustration of features of the disclosed embodiments;

FIG. 13 is an illustration of features of the disclosed embodiments;

FIG. 14 is an illustration of features of the disclosed embodiments; and

FIG. 15 is an illustration of features of the disclosed embodiments.

DETAILED DESCRIPTION

The figures and descriptions provided herein may have been simplified toillustrate aspects that are relevant for a clear understanding of theherein described apparatuses, systems, and methods, while eliminating,for the purpose of clarity, other aspects that may be found in typicalsimilar devices, systems, and methods. Those of ordinary skill may thusrecognize that other elements and/or operations may be desirable and/ornecessary to implement the devices, systems, and methods describedherein. But because such elements and operations are known in the art,and because they do not facilitate a better understanding of the presentdisclosure, for the sake of brevity a discussion of such elements andoperations may not be provided herein. However, the present disclosureis deemed to nevertheless include all such elements, variations, andmodifications to the described aspects that would be known to those ofordinary skill in the art.

Embodiments are provided throughout so that this disclosure issufficiently thorough and fully conveys the scope of the disclosedembodiments to those who are skilled in the art. Numerous specificdetails are set forth, such as examples of specific components, devices,and methods, to provide a thorough understanding of embodiments of thepresent disclosure. Nevertheless, it will be apparent to those skilledin the art that certain specific disclosed details need not be employed,and that embodiments may be embodied in different forms. As such,embodiments described herein should not be construed to limit the scopeof the disclosure. As referenced above, in some embodiments, well-knownprocesses, well-known device structures, and well-known technologies maynot be described in detail.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting. For example, asused herein, the singular forms “a”, “an” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The steps, processes, and operations described herein are notto be construed as necessarily requiring their respective performance inthe particular order discussed or illustrated, unless specificallyidentified as a preferred or required order of performance. It is alsoto be understood that additional or alternative steps may be employed,in place of or in conjunction with the disclosed aspects.

When an element or layer is referred to as being “on”, “upon”,“connected to” or “coupled to” another element or layer, it may bedirectly on, upon, connected or coupled to the other element or layer,or intervening elements or layers may be present, unless clearlyindicated otherwise. In contrast, when an element or layer is referredto as being “directly on,” “directly upon”, “directly connected to” or“directly coupled to” another element or layer, there may be nointervening elements or layers present. Other words used to describe therelationship between elements should be interpreted in a like fashion(e.g., “between” versus “directly between,” “adjacent” versus “directlyadjacent,” etc.). Further, as used herein the term “and/or” includes anyand all combinations of one or more of the associated listed items.

Yet further, although the terms first, second, third, etc. may be usedherein to describe various elements, components, regions, layers and/orsections, these elements, components, regions, layers and/or sectionsshould not be limited by these terms. These terms may be only used todistinguish one element, component, region, layer or section fromanother element, component, region, layer or section. Terms such as“first,” “second,” and other numerical terms when used herein do notimply a sequence or order unless clearly indicated by the context. Thus,a first device, element, component, region, layer or section discussedbelow could be termed a second device, element, component, region, layeror section without departing from the teachings of certain embodiments.

Certain embodiments of the disclosure provide at least an alignmentapparatus, system and method for establishing linear and/or planarpositioning between first and second surfaces of paired, placedcomponents. Such components may be mechanical, electrical or electronic,electro-magnetic, optical or photonics in nature, all by way ofnon-limiting example. Certain embodiments of the disclosure provideimproved performance and manufacturing efficiency, particularly inproducts in which planar alignments and refined placement may becritical to performance Although they may not be referenced withparticularity herein, exemplary embodiments may include additionalprocess steps in the placement and alignment of elements. Such steps mayinclude, by way of non-limiting example, applications of adhesives toparts, curing of processed parts, such as using UV or heat, or the like.

Certain embodiments of the disclosure may accomplish the foregoingthrough the use of a movable assembly comprising at least a movable yokethat “floats” within a frame and/or stator assembly. The “floating”nature of the movable assembly may be provided using alternating air andvacuum; and springs and linear elements, by way of non-limiting example.One or more air inlets, pressure ports, and vacuum ports may provide theaforementioned air and vacuum. Moreover, the referenced air and/orvacuum and/or pressure may be separately supplied to several differentelements discussed herein, such as to the gripper as compared to thechuck.

By way of further, non-limiting explanation only, such a moveableassembly may include pneumatics; and ramps, pins, bearings, bushings,and linear columns and platforms, all operatively linked to an at leastpartially spherical element or stage. Within such a bearing stage may beprovided an open area having clamping jaws and a chuck therein orproximate thereto, such as for receiving and holding a component ordevice to be aligned. Provided in association with the stage may be airand vacuum for affecting a component or device registered or otherwiseassociated with the stage. Likewise, a clamp, such as a servo clamp, amagnetic coupling, a tool changer coupling, and/or a temporary adhesivecoupling may be provided.

The component or device may, once grasped at the stage of the movableassembly, be positioned with respect other elements with which thecomponent or device is to be associated, such as in a robotic-basedmanufacturing process. This positioning may occur as a result of themovement of the component or device upon the stage into a new positionby one or more robotic elements, such as a robotic arm and/or a gantry.Once positioned relative to one another, the two components, devices orelements may be formed into, or as part of, a device or product.

Compliant, e.g., floating planar, aspects of certain embodiments of thedisclosure may provide numerous advantages. For example, the air bearingsystem provides multiple ranges of movement, and increased alignmentaccuracy, particularly for planar alignment, over the known art.

FIG. 1 illustrates an air bearing system 100 for placing or aligning adevice or component that includes a component or device placement tool102, a moveable component or device assembly 104 that may include abearing stage 106 at the top of said moveable assembly 104, and a frameand stator 110 that mechanically aligns and maintains the features ofthe bearing stage 106 and the moveable assembly 104. The bearing stage106 may receive and/or provide air, and thus may, in conjunction withthe moveable assembly, provide a “float”, and a vacuum for applicationto the component or device.

FIGS. 2A, 2B, and 2C illustrate an exemplary placement, or handoff, tool202 for placing and/or moving an electronic device 204, such as may bemoved in order to physically associate the electronic device withbearing system 102, also sometimes referred to herein as a “componentchuck.” As illustrated in FIG. 2A, the component chuck 202 may includevarious features. For example, the component chuck 202 may include ahandle 206, such as the two-finger grip handle illustrated at the top ofFIG. 2A. This handle may be any grip suitable for grasping by manual orautomated means, i.e., the grip may receive the fingers of a person toallow for the person to move an electronic device grasped by thecomponent chuck, and/or the grip may include any clasp, opening, tab,latch, adhesive, or the like that may allow for grasping of thecomponent chuck by any automated methodology, such as by a robot. Alsoillustrated in FIG. 2A is the electronic device 204 being grasped by agrasp or grippers 210 at a base of the component chuck. Also shown areone or more lever arms 212 or similar mechanical means to actuate thegripper or grippers 210 such that the electronic device 204 may begrasped by the component chuck. Also shown are one or more alignmentinterfaces 216 for alignment and physical placement of chuck 202 and/orthe device 204 associated therewith, such as with respect to thedisclosed bearing stage 100, and/or to otherwise form a mechanical orpositional interface.

FIG. 2B illustrates an exemplary two-finger manual handle 206, andadditionally, at a back portion of the two-finger handle, a release oractuator 220, such as the lever shown. Actuator 220 may allow foractuation of or release of the gripper 210, such as may be present atthe base of the component chuck 202, and as such may be suitable forcausing component or device 204 to be grasped and/or moved. FIG. 2Cillustrates gripper 210 in the form of gripping jaws on the undersideportion of the exemplary handle, wherein the gripping jaws 210 may beactuated by actuation of the lever 220 shown in FIG. 2B. Any suitablegripping methodology, such as the illustrated gripping jaws, clips,latches, hooks, adhesives, or the like may be used to grasp a componentor device to be moved with a component chuck. Such grippingmethodologies may be actuated by any automated or manual means that maybe associated with a component chuck, such as a spring close or springrelease lever as is illustrated in FIG. 2 , a button, a latch, anelectronic sensor, or any known manual or automated actuation or releasemechanism, all by way of non-limiting example.

FIG. 2C illustrates the use of an alignment interface 216 in the form oftooling pins to align and register the component chuck 202 with areceiving bearing stage 100. It will be appreciated that, although threetooling pins 216 are shown in FIG. 2C, any number of tooling pins orother registration, alignment, or mechanical interaction methodologiesapparent to the skilled artisan in light of the discussion herein may beused with certain embodiments.

FIG. 3 illustrates an exemplary air bearing device stage 302 for use incertain embodiments of the disclosure. As illustrated, the device stage302 may be spherical in shape, or otherwise suitable for multi-accessmovement, such as including rotational movement. This may allow for thestage 302 to move with the moveable assembly 104 discussed throughout tothereby allow for multi-access, including multi-planar, alignments ofthe electronic device 204 associated with the stage 302, such as withrespect to other electronic devices, chuck 202, or otherwise.

FIG. 4 illustrates an exemplary association of the stage 302 withmechanical support 402. Support 402 for the stage 302 includesmotion-limiting features 404 for aspects of the moveable assembly 104with which the stage 302 is associated. In the illustrated embodiment,the partial spherical nature of the stage 302, and the supportingcolumns 406 therefore, along with the bushings 408 of those supportcolumns 406, may provide independent structural support for the moveableassembly 104 to move in multiple axes and/or multiple planes within theframe and stator assembly 110. As additionally illustrated in FIG. 4 ,way shafts 410 and vertical link plates 412 may be provided toadditionally provide structural support and movement capabilities forthe moveable assembly 104, and hence for the stage 302 and stagingclamps associated with the moveable assembly.

Yet further, certain motion stop features for the stage 302 and clampswithin the moveable assembly 104 are shown in relation to the embodimentof FIG. 4 . For example, dual tooling plates 414, such as may be linkedwith vertical plates and shafts, may provide suitable motion limitationsfor movements of the moveable assembly 104. Also illustrated in FIG. 4 ,at the base of the moveable assembly, is a parallel gripper actuator 420which actuates the clamps/gripper jaws associated with stage 302.

FIG. 5 is an illustration of an exemplary frame and stator assembly 110suitable for use with a moveable assembly 104. As illustrated, the frameand stator 110 may include a receiving area 502 for a partiallyspherical stage 302, and one or more mechanical and support elements 504for interconnection with or direct or indirect attachment to otherelements, frames, and the moveable assembly 104.

FIG. 6 is a cutaway illustration of a cross-sectional view of anexemplary frame and stator assembly 110, and its interaction with anexemplary moveable assembly 104. In the illustrated embodiment, thestage 302 resides within a semi-spherical receiving portion 502 of theframe and stator assembly 110. Within the moveable assembly 104 andassociated with the horizon level 606 provided by the stage 302 is asupport chuck 608 for receiving a component or device 204, such as fromthe component chuck 202 discussed hereinabove. Chuck 608 may haveassociated therewith the capability to provide a vacuum, and/or an airinlet to provide an air float, as referenced herein above.Alternatively, the air and/or the vacuum may be provided about the chuck608 within stage 302 from a secondary source.

Also evident in association with the component or device support chuck608 are two gripper jaws 610 that are actuated from the gripper jawactuator 420 discussed with respect to FIG. 4 . The illustrated gripperactuator 420 may be, for example, a parallel gripper that simultaneouslyforces the gripping jaws 610 illustrated in FIG. 6 together and apart ina synchronous or substantially synchronous manner. The parallel gripperactuator 420 may additionally include various other elements andfeatures apparent to the skilled artisan, such as, for example, a vacuumscavenge, to allow for improved operation.

Further associated with the gripping jaws 610 actuated by parallelgripper actuator 420, such as at or near the base thereof, may be one ormore ramp elements 630 suitable to engage with one or moremotion-limiting pins 632. Thereby, for example, interaction of the rampportion 630 of at least one the gripping jaws 610 (at the base thereof)with the one or more pins 632 may cause linear or angular movement ofthe support chuck 608, stage 302, and/or gripping jaws 610, and hence ofthe component or device 204 associated therewith, both with respect tothe planar horizon 606 provided by the stage 302 and with respect torotational angles about the center access thereof. In short, as thegripper jaws 610 move outwardly, each respective ramp 630 may engagewith its respective pin(s) 632, and thereby the gripper jaws 610 and/orsupport chuck 608 may move vertically downward and/or angularly withrespect to either or both sides. Similarly, as the jaws come togetherand the pin “rolls down” its respective ramp, the support chuck and/orgripper jaws may move vertically upward and/or rotationally, at least inpart.

FIG. 7 provided a similar illustration to that of FIG. 6 , but at a moreproximately drawn cross-section. In the cross-sectional illustrationshown, upper and lower motion-limiting plates 702 are illustrated.Further, in association with these plates 702, there is shown a frontmechanical support 704, and one or more enabling elements 706 forvertical movement. In the illustration these vertical movement enablingelements include a pneumatic actuator 706 a and a moveable shaft 706 b,although the skilled artisan will appreciate in light of the discussionherein that other movement-enabling elements 706 may be provided, as maybe additional movement-liming elements. Also illustrated in FIG. 7 aretwo springs 710 a, 710 b that may, for example, counterbalance the massassociated with the moveable assembly to allow for optimal movement androtation of the moveable assembly. It goes without saying that anynumber of springs at any of various locations on the movable assembly104 or the frame and stator 110 may be employed to carry out thefunction of springs 710 a, 710 b, and as such the illustration in FIG. 7using two springs is merely exemplary of certain embodiments.

As such, the upper and lower plates 702 and the block, pins, shafts, andmoving elements associated therewith may, in combination, provide amoveable yoke 720 that allows for movement of the moving assembly 104.In embodiments employing pneumatic cylinders, for example, the “Hbracket” formed by plates 702 and the supporting structures thereforemay both enable and limit movement of the yoke 720, to thereby enableand/or limit movement of the moving assembly 104. Moreover, this movingyoke 720 may allow for planarization of the miniature electronic device,the chuck, and/or the stage, either together or independently, such asto allow for uniform interaction, including co-planar alignment, withother devices or planes.

FIG. 8 shows additional aspects of the moving assembly 104 of theexemplary embodiments, such as including the physical interaction withthe frame and stator assembly 110. As shown, not only may the movingassembly 104 have a number of springs 710 thereon to allow for masscounterbalancing and/or planarization as discussed above, but additionalsprings 810 a, 810 b may allow for “attachment” of or suitable physicalassociation by the moving assembly in relation to one or more portionsof the frame and stator assembly 110. Such interconnections may furtherallow for optimization of the movement of the moving assembly within theframe and stator assembly 110. Thereby, the moving assembly 104 and itsinteraction with the frame and stator assembly 110 may allow for theproviding of a working plane at or below the stage horizon level 606.Moreover, the alignment of the moveable assembly 104 may accordingly bemaintained at or close to system center, yet the moveable assembly 104may provide a suspended vertical and rotational way system.

Yet further, FIG. 8 illustrates the exemplary inclusion of a lifting ordescending lock system 820, such as with travel distance sensing 822.Thereby, FIG. 8 illustrates an embodiment in which a compliant Z accessmovement may be enabled in conjunction with the X and Y position horizonmovement provided at the stage horizon 606.

FIG. 9 illustrates additional aspects of an embodiment of a movingassembly 104. In the illustration, the chuck 608 for receiving thecomponent or device 204 is shown grasped between gripper jaws 610 thathave, in an internally synchronous manner, been moved by the gripperactuator cylinder into association with the chuck 608. Also shown inFIG. 9 are numerous movement-limiting elements 904, such as adjustabletheta stops for limiting angular movement, a tactile lock cylinder, andbushings and bearings for limiting movement in the Z axis. The skilledartisan will appreciate that these movement-limiting elements 904 areexemplary in nature only, and various other elements that either limitor support movement may form part of certain embodiments of thedisclosure. Further illustrated in the example of FIG. 9 are bothtactile springs 710, such as for counterbalancing mass in the movingassembly, and torque control springs 810 that may limit the movement ofthe moving assembly, and specifically of the stage 302, chuck 608,and/or component or device 204 associated therewith.

FIG. 9 also illustrates a tactile sensor 910. Tactile sensor 910 isexemplary of one or more sensors that may be used to sense movement, orthe stoppage thereof, by the moving assembly 104 with respect to certainembodiments disclosed throughout. Such sensors 920 may sense movementwith respect to, for example, the frame and stator assembly 110. Sensors910 may also sense process conditions, load levels, pressure levels,physical contact, performance, and the like.

FIG. 10 is an additional example of a moving assembly 104. Although FIG.10 does not include the receiving chuck 608 for the component or device204 in the illustration, it does include modified gripper jaws 1002. Ofnote, the gripper jaws 1002 illustrated provide multi-angle facets 1002a, 1002 b, such as in a triangular manner, to further provide forimproved alignment of off-aligned component or devices 204 providedbetween the gripper jaws 1002. That is, in the illustrated embodimenteach half clamp provided by a single side of the gripper jaws 1002 mayallow for variability in the X-Y position and/or pitch of a subjectcomponent or device 204, while still assuring four points of contactwith the gripper jaws 1002. Thereby, the positional stability of thecomponent or device 204 and the accuracy in the placement of thecomponent or device with respect to other secondary elements with whichit is to be interacted are improved in certain embodiments of thedisclosure. Of further note, FIG. 10 includes an additional component ordevice support arm 1006 to provide further mechanical support forcomponent or device 204, such as wherein a component or device 204 is ofa given height, or is otherwise maintained by the chuck 608 above orsubstantially above the horizon level 606 of the stage 302, and is thusin need of additional structural support prior to or upon placement.

The foregoing secondary component or device support arm 1006 is furtherillustrated with regard to the exemplary grippers 1102 of FIGS. 11A and11B. By way of nonlimiting example, the secondary support 1006 may beactuated by, for example, a pneumatic lift cylinder 1108 which allowsfor the secondary support arm to be raised. Also evident in FIGS. 11Aand 11B is the ramp plane 630 at a lower and outermost portion of thegripper jaw 610, which as referenced above, may be used for centering ofthe moveable assembly 104 and for vertical and rotational variation ofthe position of the moving assembly 104.

The primary jaws 1102 illustrated in the examples of FIGS. 11A and 11Bmay be used to control the X-Y position of a component or device 204associated therewith. FIG. 11C illustrates an exemplary secondary jaw1120 that may follow a particular component or device geometry unique tocertain uses. Of note, and as illustrated in FIG. 11C, the secondary jaw1120 may include mechanical aspects to improve gripping of a componentor device 204, such as spring loading or balancing, clamps, highfriction surfaces, or the like. Also illustrated in the example of FIG.11C is the association of a ramp plane 630 with the secondary jaw 1120,such as for the purposes indicated above with respect to the ramp plane630 of FIGS. 11A and 11B.

FIGS. 12A and 12B illustrate an inverted view of the moving assembly 104discussed herein. In the illustrations, FIG. 12A provides across-sectional view, and FIG. 12B provides a holistic view.

FIG. 13 is an illustration of an embodiment of the full assembly of theair bearing system 100, including both the moveable assembly 104 and, inphysical association with the moving assembly 104, the frame and statorassembly 110. FIG. 13 includes a ghost view of the topmost portion 1302of the frame and stator assembly 110, such that the viewer maycomprehend an exemplary physical association of the moveable assembly104 within the topmost opening of the frame and stator assembly 110.

As will be appreciated by the skilled artisan in light of the discussionherein herein, the various devices and elements disclosed may vary intheir composition. For example, support structures may be formed ofstainless steel, aluminum, composite materials, or the like, that may besuitably subjected to the processes to which the component or devicewill be exposed while physically associated with the air bearingassembly. Moreover, other materials, such as porous carbon, may be usedfor various purposes—such as wherein porous carbon, due to its enhancedpermeability, may perform differently than stainless steel when a vacuumis actuated on the subject component or device.

FIG. 14 illustrates an exemplary control sequence for the air bearingsystem discussed herein. The sequence may include delivery of acomponent or device to the air bearing stage, such as using a handofftool to which the component or device is affixed, at step 1320. Thecomponent or device may be, by non-limiting example, an optical deviceelement, such as a LED projector.

A stage, such as a spherical air bearing stage, may be centered, such asby opening synchronous parallel gripper jaws and engaging symmetricallyplaced pins against outer jaw ramps proximate to the base portions ofsaid parallel gripper jaws, at step 1322. Closure of the jaw grippersmay actuate motion enablers and/or stops, such as may enable thespherical stage to rotate and/or move linearly or in multiple planes,such as enabling rotational movement of +/−6 degrees against externalstops, at step 1330.

Thereafter, at step 1332, the handoff tool may be located, such asmanually or automatically, atop the spherical stage, and may align withthe stage. This alignment may comprise, by way of example, looselylocating alignment pins on the handoff tool into tooling holes on thestage.

At step 1334, air flow associated with the spherical stage may beswitched off, and vacuum applied to hold an initial plane. The gripperjaws may then be closed on the component or device at step 1336. Thehandoff tool is manually or automatically released and removed at step1340.

A tactile locking system, i.e., a vertical motion system, may beextended to lift the gripper jaws and the clamped component or device atstep 1344. The component or device may then be subjected to a secondsurface reference datum, such as by means of high precision compoundedx,y,z, theta powered stages, at step 1346.

At step 1348, the vacuum may be turned off, and at step 1350 the airbearing air supply may be turned on to enable a low friction float. Thez-axis actuation of the system may then again be actuated, once moreraising the component or device and now engaging it to the referencedsecond surface, at step 1352. This z-axis travel may be confirmed bysensing at step 1354, such as by a travel sensor mounted along thez-axis.

The air bearing air supply may again be turned off at step 1360, and theair bearing vacuum supply turned on anew at step 1362. At steps 1360 and1362, the tactile lock may not be implemented, but rather may remainturned off but lifted. At this juncture, the stage may be traversed to adevice assembly station, such as a lens assembly station, maintained inposition and in plane for subsequent processing, such as a lens bonding.

The foregoing apparatuses, systems and methods may also include controlof the various robotic/automation/semi-automation functionalityreferenced above. Such control may include, by way of non-limitingexample, manual control using one or more user interfaces, such as acontroller, a keyboard, a mouse, a touch screen, or the like, to allow auser to input instructions for execution by software code associatedwith the robotics and with system 100 discussed herein. Additionally,and as is well known to those skilled in the art, system control mayalso be fully automated, such as wherein manual user interaction onlyoccurs to “set up” and program the referenced functionality, i.e., auser may only initially program or upload computing code to carry outthe predetermined movements and operational sequences discussedthroughout. In either a manual or automated embodiment, the control maybe programmed, for example, to relate the known position of thecomponent or device on the stage with the desired planar position inrelation to another component.

FIG. 15 illustrates an exemplary embodiment of a computer processingsystem 400 that may be operably employed in embodiments discussedherein, including to program the robotic control, and that mayaccordingly perform the processing and logic discussed throughout. Thatis, the exemplary computing system 1400 is just one example of a systemthat may be used in accordance with herein described systems andmethods.

Computing system 1400 is capable of executing software, such as anoperating system (OS) and one or more computing applications 1490. Thesoftware may likewise be suitable for operating and/or monitoringhardware, such as via inputs/outputs (I/O), using said applications1490.

The operation of exemplary computing system 1400 is controlled primarilyby computer readable instructions, such as instructions stored in acomputer readable storage medium, such as hard disk drive (HDD) 1415,optical disk (not shown) such as a CD or DVD, solid state drive (notshown) such as a USB “thumb drive,” or the like. Such instructions maybe executed within central processing unit (CPU) 1410 to cause computingsystem 1400 to perform the disclosed operations. In many known computerservers, workstations, PLCs, personal computers, mobile devices, and thelike, CPU 1410 is implemented in an integrated circuit called aprocessor.

The various illustrative logics, logical blocks, modules, and engines,described in connection with certain embodiments disclosed herein may beimplemented or performed with any of a general purpose CPU, a digitalsignal processor (DSP), an application specific integrated circuit(ASIC), a field programmable gate array (FPGA) or other programmablelogic device, discrete gate or transistor logic, discrete hardwarecomponents, or any combination thereof, respectively acting as CPU 1410.A general-purpose processor may be a microprocessor, but, in thealternative, the processor may be any conventional processor,controller, microcontroller, or state machine. A processor may also beimplemented as a combination of computing devices, e.g., a combinationof a DSP and a microprocessor, a plurality of microprocessors, one ormore microprocessors in conjunction with a DSP core, or any other suchconfiguration.

It is appreciated that, although exemplary computing system 1400 isshown to comprise a single CPU 1410, such description is merelyillustrative, as computing system 400 may comprise a plurality of CPUs1410. Additionally, computing system 1400 may exploit the resources ofremote or parallel CPUs (not shown), for example, through local orremote communications network 1470 or some other data communicationsmeans.

In operation, CPU 1410 fetches, decodes, and executes instructions froma computer readable storage medium, such as HDD 1415. Such instructionscan be included in the software, such as the operating system (OS),executable programs/applications, and the like. Information, such ascomputer instructions and other computer readable data, is transferredbetween components of computing system 1400 via the system's maindata-transfer path. The main data-transfer path may use a system busarchitecture 1405, although other computer architectures (not shown) canbe used, such as architectures using serializers and deserializers andcrossbar switches to communicate data between devices over serialcommunication paths.

System bus 1405 may include data lines for sending data, address linesfor sending addresses, and control lines for sending interrupts and foroperating the system bus. Some busses provide bus arbitration thatregulates access to the bus by extension cards, controllers, and CPU1410. Devices that attach to the busses and arbitrate access to the busare called bus masters. Bus master support also allows multiprocessorconfigurations of the busses to be created by the addition of bus masteradapters containing processors and support chips.

Memory devices coupled to system bus 1405 can include random accessmemory (RAM) 425 and read only memory (ROM) 1430. Such memories includecircuitry that allows information to be stored and retrieved. ROMs 1430generally contain stored data that cannot be modified. Data stored inRAM 1425 can generally be read or changed by CPU 1410 or othercommunicative hardware devices. Access to RAM 1425 and/or ROM 1430 maybe controlled by memory controller 1420. Memory controller 1420 mayprovide an address translation function that translates virtualaddresses into physical addresses as instructions are executed. Memorycontroller 1420 may also provide a memory protection function thatisolates processes within the system and that isolates system processesfrom user processes. Thus, a program running in user mode can normallyaccess only memory mapped by its own process virtual address space; itcannot access memory within another process' virtual address spaceunless memory sharing between the processes has been set up.

The steps and/or actions described in connection with the aspectsdisclosed herein may be embodied directly in hardware, in a softwaremodule executed by a processor, or in a combination of the two, incommunication with memory controller 1420 in order to gain the requisiteperformance instructions. That is, the described software modules toperform the functions and provide the directions discussed hereinthroughout may reside in RAM memory, flash memory, ROM memory, EPROMmemory, EEPROM memory, registers, a hard disk, a removable disk, aCD-ROM, or any other form of storage medium known in the art. Any one ormore of these exemplary storage medium may be coupled to the processor1410, such that the processor can read information from, and writeinformation to, that storage medium. In the alternative, the storagemedium may be integral to the processor. Further, in some aspects, theprocessor and the storage medium may reside in an ASIC. Additionally, insome aspects, the steps and/or actions may reside as one or anycombination or set of instructions on an external machine readablemedium and/or computer readable medium as may be integrated through I/Oport(s) 1485, such as a “flash” drive.

In addition, computing system 400 may contain peripheral controller 1435responsible for communicating instructions using a peripheral bus fromCPU 1410 to peripherals and other hardware, such as printer 1440,keyboard 1445, and mouse 1450. An example of a peripheral bus is thePeripheral Component Interconnect (PCI) bus.

One or more hardware input/output (I/O) devices 1485 may be incommunication with hardware controller 1490. This hardware communicationand control may be implemented in a variety of ways and may include oneor more computer busses and/or bridges and/or routers. The I/O devicescontrolled may include any type of port-based hardware (and mayadditionally comprise software, firmware, or the like), and can alsoinclude network adapters and/or mass storage devices from which thecomputer system 1400 can send and receive data for the purposesdisclosed herein. The computer system 1400 may thus be in communicationwith the Internet or other networked devices/PLCs via the I/O devices1485 and/or via communications network 1470.

Display 1460, which is controlled by display controller 1455, mayoptionally be used to display visual output generated by computingsystem 1400. Display controller 1455 may also control, or otherwise becommunicative with, the display. Visual output may include text,graphics, animated graphics, and/or video, for example. Display 1460 maybe implemented with a CRT-based video display, an LCD-based display, gasplasma-based display, touch-panel, or the like. Display controller 1455includes electronic components required to generate a video signal thatis sent for display.

Further, computing system 1400 may contain network adapter 1465 whichmay be used to couple computing system 1400 to an external communicationnetwork 1470, which may include or provide access to the Internet, andhence which may provide or include tracking of and access to the processdata discussed herein. Communications network 1470 may provide access tocomputing system 1400 with means of communicating and transferringsoftware and information electronically, and may be coupled directly tocomputing system 1400, or indirectly to computing system 1400, such asvia PSTN or cellular network 1480. Additionally, communications network1470 may provide for distributed processing, which involves severalcomputers and the sharing of workloads or cooperative efforts inperforming a task. It is appreciated that the network connections shownare exemplary and other means of establishing communications linksbetween multiple computing systems 1400 may be used.

It is appreciated that exemplary computing system 1400 is merelyillustrative of a computing environment in which the herein describedsystems and methods may operate, and thus does not limit theimplementation of the herein described systems and methods in computingenvironments having differing components and configurations. That is,the concepts described herein may be implemented in various computingenvironments using various components and configurations.

Further, the descriptions of the disclosure are provided to enable anyperson skilled in the art to make or use the disclosed embodiments.Various modifications to the disclosure will be readily apparent tothose skilled in the art, and the generic principles defined herein maybe applied to other variations without departing from the spirit orscope of the disclosure. Thus, the disclosure is not intended to belimited to the examples and designs described herein, but rather is tobe accorded the widest scope consistent with the principles and novelfeatures disclosed herein.

What is claimed is:
 1. An alignment system for providing at least aplanar alignment of at least one component in relation to a referenceplane, comprising: a frame and stator assembly; a movable assemblyhaving spring limited motion within the frame and stator assembly,comprising: a floating yoke portion floating on an air stage and havingassociated therewith a tactile portion that is suitable for assessing aplane of a topmost portion of the component in relation to the referenceplane; a semi-spherical stage capable of at least rotational movement; achuck within the semi-spherical stage that is capable of at leastco-planar, post-planar, and ante-planar positioning in relation to astage plane provided by a topmost portion of the semispherical stage;and at least two synchronized gripper jaws associated with the chuck andbeing suitable for receiving and holding, at an upper portion thereof,the component, wherein the two gripper jaws comprise, at a lower portionthereof, at least two ramps capable of physically interacting with onesof the motion stops to center the chuck; wherein the movable assemblyplaces a plane provided by the topmost portion of the component into aprocessing position with respect to the reference plane so as to allowfor processing of the component and a second electronic element.
 2. Thesystem of claim 1, wherein the floating yoke stage comprises movementwith at least +/−6 degrees of rotational freedom.
 3. The system of claim1, further comprising a vacuum actuated to hold the component duringgripping by the two gripper jaws.
 4. The system of claim 1, wherein thetactile portion further comprises at least high precision compoundedx,y,z, theta powered stages.
 5. The system of claim 1 further comprisinga travel sensor for sensing at least z-axis travel of the yoke.